This document is the service manual for MerCruiser #28 Bravo Sterndrives. It provides information on maintenance, troubleshooting, removal and installation procedures. The manual begins with important safety notices and outlines the document structure. Subsequent sections cover lubrication and maintenance schedules, troubleshooting common issues, and detailed removal and installation instructions for sterndrive components. Torque specifications, lubricants and tools required are also listed throughout.
This is the Highly Detailed factory service repair manual for theMERCURY MARINER OUTBOARD 45 JET / 50 / 55 / 60, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.MERCURY MARINER OUTBOARD 45 JET / 50 / 55 / 60 Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Models covered:
45 Jet / 50 / 55 Marathon / 55 SeaPro / 60
60 Big Foot / 60 Marathon / 60 SeaPro
With Serial Numbers
United States: 0D000750 and Above
Belgium: 09671687 and Above
Service Repair Manual Covers:
General Information & Specifications
Electrical & Ignition
Ignition System
Battery, Charging System & Starting System
Timing/Synchronizing & Adjusting
Wiring Diagrams
Fuel Systems
Carburetion
Fuel Pump
Fuel Enrichment
Oil Injection
Powerhead
Mid-Section
Clamp/Swivel Brackets and Driveshaft Housing
Power Trim
Manual Tilt
Lower Unit
Standard Gear Housing
60 Big Foot, 60 SeaPro & Marathon Gear Housing
Jet Drive
Outboard Installation/Attachments
Ride-Guide Steering - Throttle/Shift Cables & Electrical Connections
Tiller Handle and Co-Pilot
Rewind Starter
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveMERCURY MARINER OUTBOARD 45 JET / 50 / 55 / 60 Service Repair Workshop Manual.
Thanks for visiting!
This is the Highly Detailed factory service repair manual for theMERCURY MARINER OUTBOARD 45 JET / 50 / 55 / 60, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.MERCURY MARINER OUTBOARD 45 JET / 50 / 55 / 60 Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Models covered:
45 Jet / 50 / 55 Marathon / 55 SeaPro / 60
60 Big Foot / 60 Marathon / 60 SeaPro
With Serial Numbers
United States: 0D000750 and Above
Belgium: 09671687 and Above
Service Repair Manual Covers:
General Information & Specifications
Electrical & Ignition
Ignition System
Battery, Charging System & Starting System
Timing/Synchronizing & Adjusting
Wiring Diagrams
Fuel Systems
Carburetion
Fuel Pump
Fuel Enrichment
Oil Injection
Powerhead
Mid-Section
Clamp/Swivel Brackets and Driveshaft Housing
Power Trim
Manual Tilt
Lower Unit
Standard Gear Housing
60 Big Foot, 60 SeaPro & Marathon Gear Housing
Jet Drive
Outboard Installation/Attachments
Ride-Guide Steering - Throttle/Shift Cables & Electrical Connections
Tiller Handle and Co-Pilot
Rewind Starter
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveMERCURY MARINER OUTBOARD 45 JET / 50 / 55 / 60 Service Repair Workshop Manual.
Thanks for visiting!
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
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Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
3. 90-863160 MAY 2000 Page i
Notice
Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal in-
jury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these prod-
ucts, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which in-
cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
4. Page ii 90-863160 MAY 2000
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the met-
ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mis-
matched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations when-
ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products
described in this manual.
Engine Mechanical Components
Many of the engine mechanical components are designed for marine applications. Unlike
automotive engines, marine engines are subjected to extended periods of heavy load
and wide-open-throttle operation and, therefore, require heavy-duty components. Special
marine engine parts have design and manufacturing specifications which are required to
provide long life and dependable performance. Marine engine parts also must be able to
resist the corrosive action of salt or brackish water that will rust or corrode standard automo-
tive parts within a short period of time.
Failure to use recommended Quicksilver service replacement parts can result in poor en-
gine performance and/or durability, rapid corrosion of parts subjected to salt water and
possibly complete failure of the engine.
Use of parts other than recommended service replacement parts, will void the warranty on
those parts which are damaged as a result of the use of other than recommended replace-
ment parts.
Replacement Parts
WARNING
Electrical, ignition and fuel system components on MerCruiser Engines and Stern-
drives are designed and manufactured to comply with U.S. Coast Guard Rules
and Regulations to minimize risks of fire or explosion.
Use of replacement electrical, ignition or fuel system components, which do not
comply to these rules and regulations, could result in a fire or explosion hazard and
should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important
that all components are properly installed and tightened. If not, any electrical or ig-
nition component opening would permit sparks to ignite fuel vapors from fuel sys-
tem leaks, if they existed.
5. 1
2
3
4
5
6
7
8
Important Information
Removal, Installation and
Adjustment
Sterndrive Unit
Transom Assembly
Power Trim
Steering Systems
Corrosion Protection
Drives
90-863160 MAY 2000 Page iii
Service Manual Outline
Section 1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal, Installation and Adjustment
A - All Models
Section 3 - Sterndrive Unit
A - Drive Shaft Housing
B - Gear Housing - Bravo One
C - Gear Housing - Bravo Two
D - Gear Housing - Bravo Three
Section 4 - Transom Assembly
A - Service Procedures Requiring Minor Disassembly
B - Service Procedures Requiring Major Disassembly
Section 5 - Power Trim
A - Oildyne Power Trim Pump
B - Trim Cylinders
C - Dual Power Trim Control
D - Auto Trim II
Section 6 - Steering Systems
A - Power Steering
B - Compact Hydraulic Steering
Section 7 - Corrosion Protection
A - All Models
Section 8 - Drives
A - All Models
13. 1
A
GENERAL INFORMATION
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1A-1
IMPORTANT INFORMATION
Section 1A - General Information
Table of Contents
How To Use This Manual 1A-2
. . . . . . . . . . . . . . .
Page Numbering 1A-2
. . . . . . . . . . . . . . . . . . .
How to Read a Parts Manual 1A-3
. . . . . . . . . . .
Introduction 1A-4
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Directional References 1A-4
. . . . . . . . . . . . . . . . .
Propeller Rotation 1A-4
. . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit 10-Hour Break-In Period
(New or With Replacement Gears) 1A-5
. . . . . .
Serial Number Locations and Engine
Designation Decal 1A-5
. . . . . . . . . . . . . . . . . . . .
14. IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28
Page 1A-2 90-863160 MAY 2000
How To Use This Manual
This manual is divided into sections that represent major components and systems. Some
sections are further divided into parts that more fully describe the component. Sections and
parts are listed at front of this manual.
Page Numbering
Two number groups appear at the bottom of each page. Following is an example and
description.
a b c d e f g
a - Section Number
b - Section Part
c - Page Number
d - Manual Part Number
e - Revision Number
f - Month Printed
g - Year Printed
15. GENERAL INFORMATION
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1A-3
How to Read a Parts Manual
Power Steering Pump Assembly
1
2
3 4
5
6
7
8
9
10
REF.
NO. PART NO. SYM. QTY. DESCRIPTION
1 90507A12 1 PUMP ASSEMBLY-Power Steering
2 36- 95805 1 CAP
3 73873A1 1 PULLEY
4 16- 41877 1 STUD
5 57- 65607T 1 V-BELT
6 32- 806684 1 HOSE-Pressure (FITTINGS ON BOTH ENDS)
7 25- 89879 1 O-RING
8 25- 806232 1 O-RING
9 13- 35048 1 LOCKWASHER (3/8 in.)
10 61990 1 CABLE TIE
REF. NO. : Number shown next to part on exploded view
PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM
part number will be given in description column.
QTY. : The quantity that must be ordered.
DESCRIPTION : Description of part, what parts are included with a part (all indented items
come with the main item above the indented parts), serial number information, and special
information.
16. IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28
Page 1A-4 90-863160 MAY 2000
Introduction
This comprehensive overhaul and repair manual is designed as a service guide for the
MerCruiser models previously listed. It provides specific information, including procedures
for disassembly, inspection, assembly and adjustment, to enable dealers and service
mechanics to repair these products.
Before attempting repairs, that procedure should first be read through to help understand
the methods and tools used and the cautions and warnings required for safety.
Directional References
Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this
service manual, all directional references are given as they appear when viewing boat from
stern, looking toward bow.
72000
STARBOARD
(RIGHT)
PORT
(LEFT)
FORE or BOW
(FRONT)
AFT or STERN
(REAR)
Propeller Rotation
Propeller rotation for sterndrive can be right hand or left hand rotation as viewed from the
aft end of the propeller.
Right Hand Rotation Left Hand Rotation
17. GENERAL INFORMATION
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1A-5
Sterndrive Unit 10-Hour Break-In Period (New or With
Replacement Gears)
1. Avoid full throttle starts.
2. DO NOT operate at any one constant speed for extended periods of time.
3. DO NOT exceed 75% of full throttle during the first 5 hours. During the next 5 hours,
operate at intermittent full throttle.
4. Drive unit should be shifted into forward gear a minimum of 10 times during break-in,
with run-in time at moderate rpm after each shift.
Serial Number Locations and Engine Designation Decal
a
Transom Assembly Serial Number Location
a - Transom Assembly Serial Number
b
a
Sterndrive Unit Serial Number Location - Port Side Decal
a - Sterndrive Unit Serial Number
b - Sterndrive Unit Gear Ratio
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20. MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-2 90-863160 MAY 2000
Lubricants / Sealants / Adhesives
Description Part Number
Quicksilver 4-Cycle 25W-40 Marine Engine Oil 92-802837A1
SAE 20W, 30W Or 40W Engine Oil Obtain Locally
Quicksilver High Performance Gear Lube 92-802854A1
Extended Life Ethylene Glycol Antifreeze Obtain Locally
Quicksilver Special Lubricant 101 92-13872A1
Quicksilver Engine Coupler Spline Grease 92-802869A1
Quicksilver Corrosion Guard Spray 92-802878 55
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2
Quicksilver Power Trim And Steering Fluid 92-802880A1
Exxon Unirex EP 2 Grease Obtain Locally
Quicksilver Hydraulic Fluid 64-826485A1
Texaco H015 92-862014A1
SeaStar Hydraulic Fluid HA5430
Approved Hydraulic Chevron Aviation Fluid A
Steering Fluids
Mobil Aero HFA Obtain Locally
Shell Aero 4
Fluid meeting MIL Specification H5606C
21. MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-3
Maintenance Schedules
Maintenance Intervals
Maintenance intervals and tasks, as shown in this schedule, or as found in previously
printed schedules, are based on an average boating application and environment.
However, individual operating habits and personal maintenance preferences can have an
impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser
has adjusted some maintenance intervals and corresponding tasks to be performed. In
some cases, this may allow for more tasks to be performed in a single visit to the servicing
dealer, rather than multiple visits. Therefore, the boat owner and servicing dealer must
discuss the current Maintenance Schedule and develop appropriate maintenance intervals
to coincide with the individual operating habits, environment and maintenance
requirements.
CAUTION
Always disconnect battery cables from battery BEFORE working around electrical
systems components to prevent injury to yourself and damage to electrical system
should a wire be accidentally shorted.
Gas Sterndrive
Routine Maintenance *
Each
Day
Start
Each
Day
End
Weekly
Every
Two
Months
Check crankcase oil (interval can be extended based on experi-
ence).
If operating in salt, brackish or polluted waters, flush cooling sys-
tem after each use.
Check sterndrive unit oil level, trim pump oil level and steering fluid
level.
Check water pickups for debris or marine growth. Check water
strainer and clean. Check coolant level.
Inspect sterndrive unit anodes and replace if 50 percent eroded.
Inspect fuel pump sight tube (if equipped) and have pump replaced
if fuel is present.
Check battery connections and fluid level.
Lubricate propeller shaft and the retorque nut (if operating in only
freshwater, this maintenance may be extended to every four
months).
Operating in saltwater only: treat engine surface with corrosion
guard.
* Only perform maintenance that applies to your particular power package
Standard Models
Horizon Models